Display device

ABSTRACT

A method of manufacturing a display apparatus including steps of forming a plurality of light emitting diode chips spaced apart from one another at a predetermined interval on a first manufacturing substrate and transferring the light emitting diode chips to a second manufacturing substrate by laser irradiation, in which the light emitting diode chips include a light emitting structure including a first-type semiconductor layer and a second-type semiconductor layer, a first-type electrode disposed on the first-type semiconductor layer, and a second-type electrode disposed on the second-type semiconductor layer.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a Continuation of U.S. patent application Ser. No.16/489,358, filed on Aug. 28, 2019, which is a National Stage Entry ofInternational Patent Application No. PCT/KR2018/002688, filed on Mar. 7,2018, and claims priority from and the benefit of U.S. ProvisionalPatent Application No. 62/470,499, filed on Mar. 13, 2017, each of whichis hereby incorporated by reference for all purposes as if fully setforth herein

BACKGROUND Field

Exemplary embodiments of the present invention relate to a method ofmanufacturing a display apparatus, and, more particularly, to a methodof transferring a light emitting diode chip to a substrate formanufacturing a display apparatus.

Discussion of the Background

A light emitting diode refers to an inorganic semiconductor device thatemits light through recombination of electrons and holes. In recentyears, light emitting diodes have been used in various fields includingdisplays, automobile lamps, general lighting, and the like. Lightemitting diodes have various advantages, such as longer lifespan, lowerpower consumption, and quicker response than conventional light sources.As such, light emitting devices using a light emitting diode arereplacing existing light sources quickly.

Recent display apparatuses, such as TVs, monitors, or electronic displayboards, display colors through a thin film transistor liquid crystaldisplay (TFT-LCD) panel, and employ light emitting diodes as a lightsource of a backlight unit for emission of the realized colors. Variousstudies have been conducted to develop a display apparatus capable ofdisplaying colors directly through light emitting diodes, instead ofusing an LCD.

In order to use light emitting diodes as a light source of a backlightunit, or for direct realization of colors, one light emitting diode maybe provided for each pixel. In this case, in order to control each ofthe light emitting diodes, an active matrix (AM) drive type or a passivematrix (PM) drive type may be employed. In the AM drive type, theluminous area of each light emitting diode being about 1/10,000 of thearea of one pixel may be sufficient, and for the PM drive type, theluminous area of each light emitting diode being about 1/100 of the areaof one pixel may be sufficient.

However, light emitting diodes having an excessively large luminous areahave a problem of low current density, causing deterioration in luminousefficacy. As such, light emitting diodes having a small luminous areawith respect to a pixel area are typically being used, such that thecurrent density flowing through the light emitting diodes may beincreased while satisfying the luminous efficacy in the pixel.

However, as the luminous area becomes smaller, the size of the lightemitting diodes becomes also smaller. As such, mounting a large numberof light emitting diodes, or replacing the light emitting diodes, whichhave a small luminous area increases manufacturing complexity.

The above information disclosed in this Background section is only forunderstanding of the background of the inventive concepts, and,therefore, it may contain information that does not constitute priorart.

SUMMARY

Methods of manufacturing a display apparatus using a light emittingdiode package according to exemplary embodiments of the invention arecapable of increasing the yield of mounting and repairing a lightemitting diode, even when the light emitting diode has a small luminousarea with respect to a pixel area of the display apparatus.

Additional features of the inventive concepts will be set forth in thedescription which follows, and in part will be apparent from thedescription, or may be learned by practice of the inventive concepts.

A method of manufacturing a display apparatus according to an exemplaryembodiment includes the steps of forming a plurality of light emittingdiode chips on a first manufacturing substrate, coupling the pluralityof the light emitting diode chips onto a second manufacturing substrate,separating the first manufacturing substrate from the plurality of thelight emitting diode chips, and transferring the plurality of lightemitting diode chips coupled onto the second manufacturing substrate toa substrate including first and second substrate electrodes.

The method of manufacturing the display apparatus may further includethe step of irradiating the first manufacturing substrate with a laserto separate the plurality of light emitting diode chips from the firstmanufacturing substrate while the plurality of light emitting diodechips are coupled to the second manufacturing substrate.

The transferring step may include coupling the plurality of lightemitting diode chips to a third manufacturing substrate, separating thesecond manufacturing substrate from the plurality of light emittingdiode chips, coupling the plurality of light emitting diode chips to theplurality of first and second substrate electrodes, and separating thethird manufacturing substrate from the plurality of light emitting diodechips.

The second manufacturing substrate may have elasticity, and thetransferring step may further include elongating the secondmanufacturing substrate along a first direction, and in the step ofcoupling the plurality of light emitting diode chips to the thirdmanufacturing substrate, the plurality of light emitting diode chipsdisposed on the elongated second manufacturing substrate may be coupledto the third manufacturing substrate.

The transferring step may include absorbing a portion of the pluralityof light emitting diode chips coupled to the second manufacturingsubstrate with a transmission device, performing at least one of heatingand ultrasonic-irradiating the second manufacturing substrate so as toseparate the portion of the plurality of light emitting diode chipsabsorbed on the transmission device from the second manufacturingsubstrate, coupling a portion of the absorbed light emitting diode chipsto the substrate, and separating the transfer device from the pluralityof light emitting diode chips coupled to the substrate.

The transferring step may include bonding a portion of the plurality oflight emitting diode chips coupled to the second manufacturing substrateto a transferring plate having a plurality of adhesive transferringportions, coupling a portion of the plurality of light emitting diodechips bonded to the transfer plate to the substrate, and separating thetransferring plate from the plurality of light emitting diode chipscoupled to the substrate.

An interval of the plurality of light emitting diode chips formed on thefirst manufacturing substrate may be the same as an interval ofsub-pixels to which the plurality of light emitting diode chips are tobe mounted.

An interval of the plurality of first and second substrate electrodesmay be the same as an interval of sub-pixels to which the plurality oflight emitting diode chips are to be mounted.

Forming the plurality of light emitting diode chips may include forminga first conductivity type semiconductor layer, an active layer, and asecond conductivity type semiconductor layer on the first manufacturingsubstrate, exposing a portion of the first conductivity typesemiconductor layer, forming first and second electrodes on the firstand second conductivity type semiconductor layers, respectively, formingan encapsulant to cover the first and second electrodes, and formingfirst and second bumps electrically connected to the first and secondelectrodes on the encapsulant, respectively.

A method of manufacturing a display apparatus according to anotherexemplary embodiment includes the steps of forming a plurality of lightemitting diode chips on a first manufacturing substrate, andtransferring at least a portion of the plurality of light emitting diodechips formed on the first manufacturing substrate to a substrate onwhich a plurality of first and second substrate electrodes are disposed.

The method of manufacturing the display apparatus may further includethe step of irradiating the first manufacturing substrate with a laserto separate the plurality of light emitting diode chips from the firstmanufacturing substrate, in which the portion of the plurality of lightemitting diode chips partially separated by the laser are transferred tothe substrate.

The transferring step may include coupling the portion of the pluralityof light emitting diode chips formed on the first manufacturingsubstrate to the first and second substrate electrodes, and separatingthe first manufacturing substrate from the portion of the plurality oflight emitting diode chips coupled to the substrate.

Forming the plurality of light emitting diode chips may include forminga light emitting structure including a first conductivity typesemiconductor layer, an active layer, and a second conductivity typesemiconductor layer on the first manufacturing substrate, exposing aportion of the first conductivity type semiconductor layer, formingfirst and second electrodes on the first and second conductivity typesemiconductor layers, respectively, forming an encapsulant to cover thelight emitting structure and the first and second electrodes, andforming first and second bumps electrically connected to the first andsecond electrodes on the encapsulant, respectively.

The encapsulant may be formed continuously on the first manufacturingsubstrate between adjacent light emitting diode chips.

An interval between the plurality of first and second substrateelectrodes may be the same as an interval between sub-pixels to whichthe plurality of light emitting diode chips are to be mounted.

A method of manufacturing a display apparatus according to yet anotherexemplary embodiment includes providing a light emitting structure on afirst substrate, the light emitting structure including a plurality oflight emitting diode chips spaced apart from each other at a firstinterval and being adhered to the first substrate, coupling at least aportion of the light emitting structure provided on the first substrateto a second substrate, selectively transferring only a first portion ofthe light emitting diode chips to the second substrate by separating thefirst substrate from the first portion of the light emitting diodechips, the second substrate including bonding portions respectivelyoverlapping the first portion of the light emitting diode chips, inwhich the bonding portions cause the first portion of the light emittingdiodes chips to be adhered to the second substrate when the firstsubstrate is separated from the first portion of the light emittingdiode chips.

The first portion of the light emitting diode chips may be spaced apartfrom each other at a second interval greater than the first interval.

The light emitting structure may further include an encapsulation layercontinuously covering each of the light emitting diode chips andcontacting the first substrate to be adhered to the first substrate.

The method may further include irradiating the first substrate with alaser to substantially separate the light emitting diode chips from thefirst substrate, while the encapsulation layer adjoins the lightemitting diode chips to the first substrate.

The bonding portions may cause the encapsulation layer to bedisconnected when the first substrate is removed from the first portionof the light emitting diodes chips.

It is to be understood that both the foregoing general description andthe following detailed description are exemplary and explanatory and areintended to provide further explanation of the invention as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are included to provide a furtherunderstanding of the invention and are incorporated in and constitute apart of this specification, illustrate exemplary embodiments of theinvention, and together with the description serve to explain theinventive concepts.

FIGS. 1A, 1B, 1C, 1D, 1E, 1F, 1G, and 1H are views illustrating a methodof transferring a light emitting diode chip of a display apparatus to asubstrate according to a first exemplary embodiment.

FIGS. 2A, 2B, 2C, 2D, 2E, 2F, 2G, 2H, and 2I are views illustrating amethod of transferring a light emitting diode chip of a displayapparatus to a substrate according to a second exemplary embodiment.

FIGS. 3A, 3B, 3C, 3D, 3E, 3F, 3G, 3H, and 3I are views illustrating amethod of transferring a light emitting diode chip of a displayapparatus to a substrate according to a third exemplary embodiment.

FIGS. 4A, 4B, 4C, 4D, 4E, 4F, 4G, 4H, and 4I are views illustrating amethod of transferring a light emitting diode chip of a displayapparatus to a substrate according to a fourth exemplary embodiment.

FIGS. 5A, 5B, 5C, and 5D are views illustrating a method of transferringa light emitting diode chip of a display apparatus to a substrateaccording to a fifth exemplary embodiment.

FIGS. 6A, 6B, 6C, 6D, 6E, 6F, and 6G are views illustrating a method ofmanufacturing a light emitting diode chip according to an exemplaryembodiment.

DETAILED DESCRIPTION

In the following description, for the purposes of explanation, numerousspecific details are set forth in order to provide a thoroughunderstanding of various exemplary embodiments or implementations of theinvention. As used herein “embodiments” and “implementations” areinterchangeable words that are non-limiting examples of devices ormethods employing one or more of the inventive concepts disclosedherein. It is apparent, however, that various exemplary embodiments maybe practiced without these specific details or with one or moreequivalent arrangements. In other instances, well-known structures anddevices are shown in block diagram form in order to avoid unnecessarilyobscuring various exemplary embodiments. Further, various exemplaryembodiments may be different, but do not have to be exclusive. Forexample, specific shapes, configurations, and characteristics of anexemplary embodiment may be used or implemented in another exemplaryembodiment without departing from the inventive concepts.

Unless otherwise specified, the illustrated exemplary embodiments are tobe understood as providing exemplary features of varying detail of someways in which the inventive concepts may be implemented in practice.Therefore, unless otherwise specified, the features, components,modules, layers, films, panels, regions, and/or aspects, etc.(hereinafter individually or collectively referred to as “elements”), ofthe various embodiments may be otherwise combined, separated,interchanged, and/or rearranged without departing from the inventiveconcepts.

The use of cross-hatching and/or shading in the accompanying drawings isgenerally provided to clarify boundaries between adjacent elements. Assuch, neither the presence nor the absence of cross-hatching or shadingconveys or indicates any preference or requirement for particularmaterials, material properties, dimensions, proportions, commonalitiesbetween illustrated elements, and/or any other characteristic,attribute, property, etc., of the elements, unless specified. Further,in the accompanying drawings, the size and relative sizes of elementsmay be exaggerated for clarity and/or descriptive purposes. When anexemplary embodiment may be implemented differently, a specific processorder may be performed differently from the described order. Forexample, two consecutively described processes may be performedsubstantially at the same time or performed in an order opposite to thedescribed order. Also, like reference numerals denote like elements.

When an element, such as a layer, is referred to as being “on,”“connected to,” or “coupled to” another element or layer, it may bedirectly on, connected to, or coupled to the other element or layer orintervening elements or layers may be present. When, however, an elementor layer is referred to as being “directly on,” “directly connected to,”or “directly coupled to” another element or layer, there are nointervening elements or layers present. To this end, the term“connected” may refer to physical, electrical, and/or fluid connection,with or without intervening elements. Further, the D1-axis, the D2-axis,and the D3-axis are not limited to three axes of a rectangularcoordinate system, such as the x, y, and z-axes, and may be interpretedin a broader sense. For example, the D1-axis, the D2-axis, and theD3-axis may be perpendicular one another, or may represent differentdirections that are not perpendicular to one another. For the purposesof this disclosure, “at least one of X, Y, and Z” and “at least oneselected from the group consisting of X, Y, and Z” may be construed as Xonly, Y only, Z only, or any combination of two or more of X, Y, and Z,such as, for instance, XYZ, XYY, YZ, and ZZ. As used herein, the term“and/or” includes any and all combinations of one or more of theassociated listed items.

Although the terms “first,” “second,” etc. may be used herein todescribe various types of elements, these elements should not be limitedby these terms. These terms are used to distinguish one element fromanother element. Thus, a first element discussed below could be termed asecond element without departing from the teachings of the disclosure.

Spatially relative terms, such as “beneath,” “below,” “under,” “lower,”“above,” “upper,” “over,” “higher,” “side” (e.g., as in “sidewall”), andthe like, may be used herein for descriptive purposes, and, thereby, todescribe one elements relationship to another element(s) as illustratedin the drawings. Spatially relative terms are intended to encompassdifferent orientations of an apparatus in use, operation, and/ormanufacture in addition to the orientation depicted in the drawings. Forexample, if the apparatus in the drawings is turned over, elementsdescribed as “below” or “beneath” other elements or features would thenbe oriented “above” the other elements or features. Thus, the exemplaryterm “below” can encompass both an orientation of above and below.Furthermore, the apparatus may be otherwise oriented (e.g., rotated 90degrees or at other orientations), and, as such, the spatially relativedescriptors used herein interpreted accordingly.

The terminology used herein is for the purpose of describing particularembodiments and is not intended to be limiting. As used herein, thesingular forms, “a,” “an,” and “the” are intended to include the pluralforms as well, unless the context clearly indicates otherwise. Moreover,the terms “comprises,” “comprising,” “includes,” and/or “including,”when used in this specification, specify the presence of statedfeatures, integers, steps, operations, elements, components, and/orgroups thereof, but do not preclude the presence or addition of one ormore other features, integers, steps, operations, elements, components,and/or groups thereof. It is also noted that, as used herein, the terms“substantially,” “about,” and other similar terms, are used as terms ofapproximation and not as terms of degree, and, as such, are utilized toaccount for inherent deviations in measured, calculated, and/or providedvalues that would be recognized by one of ordinary skill in the art.

Various exemplary embodiments are described herein with reference tosectional and/or exploded illustrations that are schematic illustrationsof idealized exemplary embodiments and/or intermediate structures. Assuch, variations from the shapes of the illustrations as a result, forexample, of manufacturing techniques and/or tolerances, are to beexpected. Thus, exemplary embodiments disclosed herein should notnecessarily be construed as limited to the particular illustrated shapesof regions, but are to include deviations in shapes that result from,for instance, manufacturing. In this manner, regions illustrated in thedrawings may be schematic in nature and the shapes of these regions maynot reflect actual shapes of regions of a device and, as such, are notnecessarily intended to be limiting.

Unless otherwise defined, all terms (including technical and scientificterms) used herein have the same meaning as commonly understood by oneof ordinary skill in the art to which this disclosure is a part. Terms,such as those defined in commonly used dictionaries, should beinterpreted as having a meaning that is consistent with their meaning inthe context of the relevant art and should not be interpreted in anidealized or overly formal sense, unless expressly so defined herein.

Hereinafter, exemplary embodiments of the present disclosure will bedescribed in detail with reference to the accompanying drawings.

FIGS. 1A to 1H are views illustrating a method of transferring a lightemitting diode chip of a display apparatus to a substrate according to afirst exemplary embodiment.

Referring to FIG. 1A to 1H, the method of transferring a light emittingdiode chip 120 to a substrate 110 in the display apparatus according tothe first exemplary embodiment will be described.

Referring to FIG. 1A, a plurality of light emitting diode chips 120 aredisposed on a first manufacturing substrate 51. The plurality of lightemitting diode chips 120 may be formed separately and transferred to thefirst manufacturing substrate 51, or the plurality of light emittingdiode chips 120 may be grown and manufactured on the first manufacturingsubstrate 51. The first manufacturing substrate 51 may have aninsulating material as the substrate 110, and may have a predeterminedthickness.

The plurality of light emitting diode chips 120 may be spaced apart fromone another at a predetermined interval P on the first manufacturingsubstrate 51. In this case, the interval P between the light emittingdiode chips 120 may correspond to an interval between subpixels of thedisplay apparatus.

Each of the light emitting diode chips 122 may emit light in response toan external power source applied thereto, and include a light emittingstructure 29, an n-type electrode 3I, a p-type electrode 33, an n-typebump 35, a p-type bump 37, and an encapsulant 39. The light emittingstructure 29 may include an n-type semiconductor layer 23, an activelayer 25, and a p-type semiconductor layer 27.

Each of the n-type semiconductor layer 23, the active layer 25, and thep-type semiconductor layer 27 may include Group III-V based compoundsemiconductors. For example, each of the n-type semiconductor layer 23,the active layer 25, and the p-type semiconductor layer 27 may includenitride semiconductors, such as (Al, Ga, In)N. The n-type semiconductorlayer 23 may be interchangeably placed with the p-type semiconductorlayer 27.

The n-type semiconductor layer 23 may be a conductive semiconductorlayer including n-type dopants (for example, Si), and the p-typesemiconductor layer 27 may be a conductive semiconductor layer includingp-type dopants (for example, Mg). The active layer 25 is interposedbetween the n-type semiconductor layer 23 and the p-type semiconductorlayer 27, and may include a multi-quantum well (MQW) structure. Thecomposition of the active layer 25 may be determined to emit lighthaving a desired peak wavelength.

The light emitting structure 29 may have a structure, in which then-type semiconductor layer 23, the active layer 25, and the p-typesemiconductor layer 27 are sequentially stacked one over another. Inaddition, a portion of the n-type semiconductor layer 23 may be exposedupward by partially removing the p-type semiconductor layer 27 and theactive layer 25.

The p-type electrode 33 is disposed over the p-type semiconductor layer27 to be electrically connected to the p-type semiconductor layer 27,and the n-type electrode 31 is disposed over the exposed portion of then-type semiconductor layer 23 to be electrically connected to the n-typesemiconductor layer 23. More particularly, the light emitting diode chip122 according to the illustrated exemplary embodiment may have ahorizontal structure, in which the n-type electrode 31 and the p-typeelectrode 33 are arranged in the same direction.

The encapsulant 39 may be disposed on an upper portion of the lightemitting structure 29 to cover the n-type electrode 31, the p-typeelectrode 33, and the light emitting structure 29. The encapsulant 39has electrically insulating properties and may protect the lightemitting structure 29, the n-type electrode 31, and the p-type electrode33 from external environments. According to an exemplary embodiment, theencapsulant 39 may be formed of a transparent material. Alternatively,the encapsulant 39 may be formed of an opaque material or a translucentmaterial. The encapsulant 39 may have substantially the same width asthe light emitting structure 29.

Each of the n-type bump 35 and the p-type bump 37 may be disposed tocover a portion of an upper surface of the encapsulant 39. The n-typebump 35 may be electrically connected to the n-type electrode 31, andthe p-type bump 37 may be electrically connected to the p-type electrode33 through via-holes passing through the encapsulant 39. The n-type bump35 and the p-type bump 37 are spaced apart from each other on the uppersurface of the encapsulant 39 to be electrically insulated from eachother.

When the plurality of light emitting diode chips 120 is disposed on thefirst manufacturing substrate 51 as described above, the firstmanufacturing substrate 51 is turned upside down and the plurality oflight emitting diode chips 120 are coupled to a second manufacturingsubstrate 53 as shown in FIG. 1B. Accordingly, the n-type bumps 35 andthe p-type bumps 37 of the plurality of light emitting diode chips 120are in contact with the second manufacturing substrate 53.

As shown in FIG. 1C, the first manufacturing substrate 51 is irradiatedwith a laser. As such, the first manufacturing substrate 51 and theplurality of light emitting diode chips 120 may be separated by theirradiation process.

Thus, as shown in FIG. 1D, the plurality of light emitting diode chips120 may be transferred to the second manufacturing substrate 53.

Referring to FIG. 1E, a third manufacturing substrate 55 is coupled toan upper portion of the plurality of light emitting diode chips 120.When the third manufacturing substrate 55 is coupled to the plurality oflight emitting diode chips 120, the second manufacturing substrate 53 isremoved as shown in FIG. 1F.

The second manufacturing substrate 53 and the third manufacturingsubstrate 55 may be substantially the same as the first manufacturingsubstrate 51.

Referring to FIG. 1G, the plurality of light emitting diode chips 120coupled to the third manufacturing substrate 55 may be transferred tothe substrate 110. The substrate 110 is provided to support the lightemitting diode chip 120. The substrate 110 may have an insulatingmaterial, and may have a predetermined thickness.

The substrate 110 may include a first substrate electrode 132 and asecond substrate electrode 134 formed thereon. The first substrateelectrode 132 may extend from an upper surface of the substrate 110 to alower surface thereof, and the second substrate electrode 134 may extendfrom the upper surface of the substrate 110 to the lower surfacethereof. The first substrate electrode 132 and the second substrateelectrode 134 may be spaced apart and electrically insulated from eachother.

The substrate 110 may further include a fourth manufacturing substrate57 disposed under the substrate 110, and a buffer layer may be formedbetween the substrate 110 and the fourth manufacturing substrate 57. Thefourth manufacturing substrate 57 may have substantially the samematerial as the first manufacturing substrate 51, and may be used in asubsequent process.

A bonding portion S may be applied on the first substrate electrode 132and the second substrate electrode 134.

Accordingly, the p-type bumps 37 and the n-type bumps 35 of the lightemitting diode chip 120, as shown in FIG. 1H, are electrically coupledto the first substrate electrode 132 and the second substrate electrode134, respectively. When the light emitting diode chip 120 is coupled tothe substrate 110, the third manufacturing substrate 55 disposed overthe plurality of light emitting diode chips 120 may be removed.

FIGS. 2A to 2I are views illustrating a method of transferring a lightemitting diode chip of a display apparatus to a substrate according to asecond exemplary embodiment.

Referring to FIGS. 2A to 2I, the method of transferring a light emittingdiode chip 120 to the substrate 110 in the display apparatus accordingto the second exemplary embodiment will be described.

Referring to FIG. 2A, a plurality of light emitting diode chips 120 aredisposed on a first manufacturing substrate 51′. In the illustratedexemplary embodiment, the first manufacturing substrate 51′ may have amaterial different from the first manufacturing substrate 51 describedabove with reference to FIG. 1A. The process of disposing the pluralityof light emitting diode chips 120 on the first manufacturing substrate51′ of the illustrated exemplary embodiment may be performed after theprocess shown with reference to FIGS. 1A to 1D.

The first manufacturing substrate 51′ may be formed of an insulatingmaterial having elasticity. The first manufacturing substrate 51′ may beelongated in the longitudinal direction. Accordingly, a distance betweenthe plurality of light emitting diode chips 120 may become greater.

In this state, as shown in FIG. 2B, a second manufacturing substrate 53′is coupled to an upper portion of the plurality of light emitting diodechips 120. In this case, the second manufacturing substrate 53′ may havean insulating material having elasticity as the first manufacturingsubstrate 51′.

Referring to FIG. 2C, the first manufacturing substrate 51′ is separatedfrom the plurality of light emitting diode chips 120, the secondmanufacturing substrate 53′ is elongated in the longitudinal direction,such that a distance between the plurality of light emitting diode chipsmay be increased.

While the distance between the plurality of light emitting diode chips120 is increased by elongating the second manufacturing substrate 53′,as shown in FIG. 2D, a third manufacturing substrate 55′ havingelasticity is coupled to the plurality of light emitting diode chips120.

Then, as shown in FIG. 2E, the second manufacturing substrate 53′ isseparated from the plurality of light emitting diode chips 120, and thethird manufacturing substrate 55′ is elongated in the longitudinaldirection to increase the distance between the plurality of lightemitting diode chips 120. In this case, the third manufacturingsubstrate 55′ may have an insulating material having elasticity, as inthe first manufacturing substrate 51′.

While the third manufacturing substrate 55′ is elongated, as shown inFIG. 2F, a fourth manufacturing substrate 57 is coupled to the pluralityof light emitting diode chips 120. Then, as shown in FIG. 2G, the thirdmanufacturing substrate 55′ is separated.

While the plurality of light emitting diode chips 120 are coupled to thefourth manufacturing substrate 57, the fourth manufacturing substrate 57may be coupled onto the substrate 110. In this case, a first substrateelectrode 132′ and a second substrate electrode 134′ may be disposed onthe substrate 110 as in the first exemplary embodiment. However, thefirst substrate electrode 132′ and the second electrode 134′ have shapesdifferent from those of the first exemplary embodiment. The firstsubstrate electrode 132′ extends from the upper surface of the substrate110 to the lower surface thereof through the substrate 110. A portion ofthe first substrate electrode 132′ is disposed on the upper surface ofthe substrate 110 and another portion of the first substrate electrode132′ is disposed on the lower surface of the substrate 110, such thatboth portions of the first substrate electrode 132′ are electricallyconnected to each other through a via-hole formed in the substrate 110.As in the first substrate electrode 132′, portions of the secondsubstrate electrode 134′ are disposed on the upper and lower surfaces ofthe substrate 110, respectively, and are electrically connected to eachother through the via-hole formed in the substrate 110. In this case,the first substrate electrode 132′ may be spaced apart from the secondsubstrate electrode 134′ to be electrically insulated from each other.

The first substrate electrode 132′ and the second substrate electrode134′ disposed on the upper surface of the substrate 110 may beelectrically connected to an n-type bump 35 and a p-type bump 37,respectively, and a bonding portion S may be applied on the firstsubstrate electrode 132′ and the second substrate electrode 134′ to beelectrically coupled to the n-type bump 35 and the p-type bump 37,respectively.

When the plurality of light emitting diode chips 120 are coupled to thesubstrate 110, the fourth manufacturing substrate 57, as shown in FIG.2I, may be removed. A fifth manufacturing substrate 59 may be disposedunder the substrate 110, and a buffer layer may be disposed between thesubstrate 110 and the fifth manufacturing substrate 59.

FIGS. 3A to 3I are views illustrating a method of transferring a lightemitting diode chip of a display apparatus to a substrate according to athird exemplary embodiment.

Referring to FIGS. 3A to 3I, the method of transferring a light emittingdiode chip 120 to the substrate 110 in the display apparatus accordingto the third exemplary embodiment will be described.

Referring to FIG. 3A, a plurality of light emitting diode chips 120 aredisposed on a first manufacturing substrate 51. In the illustratedexemplary embodiment, the first manufacturing substrate 51 on which theplurality of light emitting diode chips 120 are disposed issubstantially the same as that of FIG. 1A, but FIG. 3A may be aninverted view showing the light emitting diode chip 120 rotated by 180degrees.

As shown in FIG. 3B, a second manufacturing substrate 53 is coupled to alower portion of the plurality of light emitting diode chips 120, andirradiation is performed over the first manufacturing substrate 51 witha laser as shown in FIG. 3C. Accordingly, the plurality of lightemitting diode chips 120 and the first manufacturing substrate 51 may beseparated from each other.

FIG. 3D shows a state in which the plurality of light emitting diodechips 120 and the first manufacturing substrate 51 are separated fromeach other.

Referring to FIG. 3E, when the plurality of light emitting diode chips120 are mounted on the second manufacturing substrate 53, a transferdevice 300 is placed above the light emitting diode chips 120 totransfer a portion of the plurality of light emitting diode chips 120.The transfer device 300 may transfer the light emitting diode chips 120from the second manufacturing substrate 53 to another location byabsorbing the light emitting diode chips 120 disposed at predeterminedintervals. In this case, the transfer device 300 may absorb the portionof the plurality of light emitting diode chips 120 disposed on thesecond manufacturing substrate 53 to be transferred.

For example, the transfer device 300 may absorb one of the threeadjacent light emitting diode chips 120 for transfer, however, theinventive concepts are not limited to a particular number of the lightemitting diode chips 120 to be transferred by the transfer device 300.

Then, as shown in FIG. 3F, when the transfer device 300 absorbs theplurality of light emitting diode chips 120, a heater 400 may beoperated under the corresponding light emitting diode chip 120. Theheater 400 may apply heat to cause ultrasonic-vibration in the secondmanufacturing substrate 53 on which the light emitting diode chip 120 isdisposed, to separate the light emitting diode chip 120 absorbed by thetransfer device 300 from the second manufacturing substrate 53.

Then, as shown in FIG. 3G, the plurality of light emitting diode chips120 may be absorbed to the transfer device 300.

The plurality of light emitting diode chips 120 absorbed to the transferdevice 300 may be moved, and coupled to the substrate 110 as shown inFIG. 3H. In this case, a first substrate electrode 132 and a secondsubstrate electrode 134 may be disposed on the substrate 110. Inaddition, a third manufacturing substrate 55 and a fourth manufacturingsubstrate 57 may be coupled to a lower portion of the substrate 110.

Then, as shown in FIG. 3I, the transfer device 300 is separated from theplurality of light emitting diode chips 120 coupled onto the substrate110. In addition, the third manufacturing substrate 55 coupled to thelower portion of the fourth manufacturing substrate 57 may be heated,for example, to be separated.

In the illustrated exemplary embodiment, each of the secondmanufacturing substrate 53, the third manufacturing substrate 55, andthe fourth manufacturing substrate 57 may be substantially the same asthe first manufacturing substrate 51 of the first exemplary embodiment.Moreover, the third manufacturing substrate 55 may withstand thepressure that may be generated when the plurality of light emittingdiode chips 120 are coupled to the substrate 110 from the transferdevice 300.

FIGS. 4A to 4I are views illustrating a method of transferring a lightemitting diode chip of a display apparatus to a substrate according to afourth exemplary embodiment.

Referring to FIGS. 4A to 4I, the method of transferring a light emittingdiode chip 120 to the substrate 110 in the display apparatus accordingto the fourth exemplary embodiment will be described.

Referring to FIG. 4A, a plurality of light emitting diode chips 120 aredisposed on a first manufacturing substrate 51. The processesillustrated in FIGS. 4A to 4D are substantially the same as in the thirdexemplary embodiment, and thus, repeated descriptions thereof will beomitted to avoid redundancy.

Referring to FIG. 4E, the plurality of light emitting diode chips 120are disposed on a second manufacturing substrate 53, and a transferringplate 500 is placed above the light emitting diode chips 120. Thetransferring plate 500 performs substantially the same function as thetransfer device 300 in the third exemplary embodiment. However, thetransferring plate 500 according to the illustrated exemplary embodimentmay include a plurality of adhesive transferring portions 510.Accordingly, a portion of the plurality of light emitting diode chips120 is bonded to the adhesive transferring portion 510, and is coupledto the transferring plate 500. The plurality of adhesive transferringportions 510 may be regularly disposed in the transferring plate 500according to rows and columns, as shown in FIG. 4F.

Then, the plurality of light emitting diodes are coupled to thetransferring plate 500 as shown in FIG. 4G.

The plurality of light emitting diode chips 120 bonded to thetransferring plate 500, as shown in FIG. 4H, may be moved and coupled tothe substrate 110. Then, as shown in FIG. 4I, the plurality of lightemitting diode chips 120 coupled to the substrate 100 may be separatedfrom the transferring plate 500. The substrate 110 is substantially thesame as that in the third exemplary embodiment, and thus, repeateddescriptions thereof will be omitted.

FIGS. 5A to 5D are views illustrating a method of transferring a lightemitting diode chip of a display apparatus to a substrate according to afifth exemplary embodiment.

Referring to FIGS. 5A to 5D, the method of transferring a light emittingdiode chip 120 to the substrate 110 in the display apparatus accordingto the fifth exemplary embodiment will be described.

Referring to FIG. 5A, a plurality of light emitting diode chips 120 aredisposed on a first manufacturing substrate 51. In the illustratedexemplary embodiment, the plurality of light emitting diode chips 120may be substantially the same as those of the first exemplaryembodiment. However, when the light emitting diode chips 120 are grownand manufactured on the first manufacturing substrate 51, an encapsulant39 of the light emitting diode chip 120 may be connected to an adjacentlight emitting diode chip 120, as shown in FIG. 5A.

Then, as shown in FIG. 5B, the first manufacturing substrate 51 on whichthe plurality of light emitting diode chips 120 are disposed may beinverted to be irradiated with a laser over the first manufacturingsubstrate 51. Accordingly, the first manufacturing substrate 51 and eachlight emitting diode chip 120 may be partially separated. At this time,one of the semiconductor layers of the light emitting diode chip 120that contacts the first manufacturing substrate 51 may be separated fromthe first manufacturing substrate 51 by irradiation with a laser, buteach light emitting diode chip 120 may not be completely separated fromthe first manufacturing substrate 51, since the encapsulant 39 isconnected with the adjacent light emitting diode chip 120.

In this state, referring to FIG. 5C, the first manufacturing substrate51 is disposed on the substrate 110, so that a portion of the pluralityof light emitting diode chips 120 is coupled to the substrate 110. Atthis time, a first substrate electrode 132′ and a second substrateelectrode 134′ are disposed on the substrate 110 as in the secondexemplary embodiment, and a bonding portion S may be applied on thefirst substrate electrode 132′ and the second substrate electrode 134′.As such, the light emitting diode chip 120 in contact with the firstsubstrate electrode 132′ and the second substrate electrode 134′ of thesubstrate 110 may be coupled onto the substrate 110.

More particularly, as shown in FIG. 5C, a plurality of first substrateelectrodes 132′ and the second substrate electrodes 134′ disposed on thesubstrate 110 is not disposed at the same interval as that of theplurality of light emitting diode chips 120 disposed on the firstmanufacturing substrate 51. The plurality of first substrate electrodes132′ and the second substrate electrodes 134′ may be disposed at aninterval greater than that of the plurality of light emitting diodechips 120 disposed on the first manufacturing substrate 51. Accordingly,when the first manufacturing substrate 51 and the substrate 110 faceeach other, a portion of the plurality of light emitting diode chips 120disposed on the first manufacturing substrate 51 may be disposed on thesubstrate 110.

In this case, since the bonding portion S is applied on the firstsubstrate electrode 132′ and the second substrate electrode 134′, onlythe plurality of light emitting diode chips 120 coupled to the bondingportion S are coupled onto the substrate 110. The drawings show thatonly one of the two light emitting diode chips 120 is coupled onto thesubstrate 110, however, the inventive concepts are not limited thereto.

Then, as shown in FIG. 5D, the plurality of light emitting diode chips120 may be disposed on the substrate 110. In this case, an interval ofthe plurality of light emitting diode chips 120 disposed on thesubstrate 110 may correspond to an interval between sub-pixels of thedisplay apparatus.

In addition, the substrate 110 according to the illustrated exemplaryembodiment is substantially the same as the substrate 110 in the secondexemplary embodiment through the fourth exemplary embodiment, and thus,repeated descriptions thereof will be omitted.

FIGS. 6A to 6G are views showing a method of manufacturing a lightemitting diode chip according to an exemplary embodiment.

A process of manufacturing a light emitting diode chip 120 on a firstmanufacturing substrate 51 in the display apparatus will be describedwith reference to FIGS. 6A to 6G.

In FIGS. 6A through 6G, images shown on the right side are plan views ofcorresponding cross-sectional views shown on the left side.

Referring to FIG. 6A, an n-type semiconductor layer 23, an active layer25, and a p-type semiconductor layer 27 are grown on the firstmanufacturing substrate 51.

Subsequently, as shown in FIG. 6B, the active layer 25 and the p-typesemiconductor layer 27 are partially removed to expose the n-typesemiconductor layer 23. In this case, the n-type semiconductor layer 23exposed in an upward direction may have substantially a T-shape in planview, as shown in FIG. 6B.

Then, an n-type electrode 31 is formed on the exposed n-typesemiconductor layer 23 as shown in FIG. 6C. The n-type electrode 31 mayalso be formed in substantially a T-shape as the exposed n-typesemiconductor layer 23. The n-type electrode 31 may be spaced apart fromthe active layer 25 and the p-type semiconductor layer 27 to beinsulated therefrom.

Next, as shown in FIG. 6D, a p-type electrode 33 is formed over thep-type semiconductor layer 27. In this case, the p-type electrode 33 maybe formed in substantially a left-opened rectangular shape in accordancewith the shape of the upper surface of the p-type semiconductor layer27.

Then, referring to FIG. 6E, an encapsulant 39 may be formed to covereach of the n-type electrode 31, the p-type electrode 33, and the lightemitting structure 29. The encapsulant 39 is formed to havesubstantially the same width as that of the light emitting structure 29.Accordingly, the encapsulant 39 may not cover side surfaces of the lightemitting structure 29.

Next, referring to FIG. 6F, a portion of the encapsulant 39 is etched toform a via exposing the n-type electrode 31 and the p-type electrode 33.At this time, the n-type electrode 31 and the p-type electrode 33exposed through the via may be a portion of the n-type electrode 31 andthe p-type electrode 33, respectively.

Then, referring to FIG. 6G, an n-type bump 35 and a p-type bump 37 areformed over the encapsulant 39, respectively. The n-type bump 35 isformed over the n-type electrode 31, and the p-type bump 37 is disposedover the p-type electrode 33. The n-type bump 35 may be electricallyconnected to the n-type electrode 31 through the via formed in theencapsulant 39, and the p-type bump 37 may be electrically connected tothe p-type electrode 33 through the via formed in the encapsulant 39.

The light emitting diode chip 120 may be manufactured on the firstmanufacturing substrate 51 by the manufacturing method according toexemplary embodiments described above.

According to exemplary embodiments, even when luminous area of a lightemitting diode chip is reduced and an amount of the supplied current issmall, the current density flowing through the light emitting diode chipmay be increased.

In addition, by increasing the size of a light emitting diode package tobe larger than a size of the light emitting diode chip, the yield of themanufacturing process of a display apparatus and the replacement processmay be improved, even when the light emitting diode chip has a smallluminous area.

Although certain exemplary embodiments and implementations have beendescribed herein, other embodiments and modifications will be apparentfrom this description. Accordingly, the inventive concepts are notlimited to such embodiments, but rather to the broader scope of theappended claims and various obvious modifications and equivalentarrangements as would be apparent to a person of ordinary skill in theart.

What is claimed is:
 1. A display apparatus, comprising: a substratelongitudinally extending along a first direction having a firstsubstrate electrode and a second substrate electrode; and a plurality oflight emitting sources disposed on the substrate and spaced apart fromone another at a predetermined interval, wherein the light emittingsource comprises: a light emitting structure having an n-typesemiconductor layer, an active layer, and a p-type semiconductor layer;a p-type electrode disposed over the p-type semiconductor layer andelectrically connected to the p-type semiconductor layer; and an n-typeelectrode disposed over the n-type semiconductor layer and electricallyconnected to the n-type semiconductor layer, wherein the n-typeelectrode and the p-type electrode are arranged in a same direction,wherein the first substrate electrode extends from an upper surface ofthe substrate facing the light emitting sources to a lower surfacethereof and is electrically connected to the p-type electrode, the firstsubstrate electrode including an upper portion having a substantiallyflat top surface and disposed on the upper surface of the substrate anda lower portion disposed on the lower surface of the substrate, whereinthe second substrate electrode extends from the upper surface of thesubstrate to the lower surface thereof and is electrically connected tothe n-type electrode, the second substrate electrode including an upperportion having a substantially flat top surface and disposed on theupper surface of the substrate and a lower portion disposed on the lowersurface of the substrate, and wherein the upper portion of the firstsubstrate electrode of a first light emitting source and the upperportion of the second substrate electrode of a second light emittingsource adjacent to the first light emitting source is spaced apart by afirst distance less than a width of the light emitting source along thefirst direction.
 2. The display apparatus of claim 1, further comprisesan encapsulant disposed on an upper surface of the light emittingstructure.
 3. The display apparatus of claim 2, wherein the encapsulantcovers a portion of the n-type electrode and a portion of the p-typeelectrode.
 4. The display apparatus of claim 2, wherein the encapsulantcomprises a transparent material.
 5. The display apparatus of claim 2,wherein the encapsulant comprises f an opaque material or a translucentmaterial.
 6. The display apparatus of claim 2, further comprising: ann-type bump electrically connected to the n-type electrode; and a p-typebump electrically connected to the p-type electrode.
 7. The displayapparatus of claim 6, wherein each of the n-type bump and the p-typebump are disposed to cover a portion of an upper surface of theencapsulant.
 8. The display apparatus of claim 6, wherein in one of thelight emitting sources: the p-type electrode and the n-type electrodeare spaced apart by a first distance; the n-type bump and the p-typebump are spaced apart by a second distance greater than the firstdistance; the upper portions of the first and second substrateelectrodes are spaced apart by a third distance greater than the seconddistance; and the lower portions of the first and second substrateelectrodes are spaced apart by a fourth distance greater than the thirddistance.
 9. The display apparatus of claim 6, wherein the encapsulanthas a plurality of via holes.
 10. The display apparatus of claim 9,wherein the p-type bump is electrically connected to the p-typeelectrode through the via hole passing through the encapsulant.
 11. Thedisplay apparatus of claim 9, wherein the n-type bump is electricallyconnected to the n-type electrode through the via hole passing throughthe encapsulant.